Picking systems and methods

ABSTRACT

A system for picking items from a containerised storage system is described. The items are stored in storage bins in stacks within a framework comprising a grid system disposed above the stacks of bins. Robotic devices are disposed on the grid, the devices acting so as to pick containers from the stacks of bins. The storage system is provided with at least one picking device for picking items from bins and depositing them directly in delivery containers DT.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/094,023, filed on Nov. 10, 2020, which is a continuation of U.S.patent application Ser. No. 15/775,623, filed on May 11, 2018, which inturn is a National Stage Application of PCT/EP2016/077476, filed on Nov.11, 2016, which claims priority to UK Patent Application Nos.GB1519931.8, GB1519930.0 and GB1519929.2 filed on 11 Nov. 2015, theentire contents of which are hereby incorporated by reference.

The present invention relates to picking systems and methods. Morespecifically but not exclusively, it relates to robotic picking systemsfor picking objects from storage systems having storage bins in stacks,the stacks being located within a grid structure.

BACKGROUND

Some commercial and industrial activities require systems that enablethe storage and retrieval of a large number of different products. Oneknown type of system for the storage and retrieval of items in multipleproduct lines involves arranging storage bins or containers in stacks ontop of one another, the stacks being arranged in rows. The storage binsare removed from the stacks and accessed from above by load handlingdevices, removing the need for aisles between the rows and allowing morecontainers to be stored in a given space.

DESCRIPTION OF RELATED ART

Methods of handling containers stacked in rows have been well known fordecades. In some such systems, for example as described in U.S. Pat. No.2,701,065, to Bertel comprise freestanding stacks of containers arrangedin rows in order to reduce the storage volume associated with storingsuch containers but yet still providing access to a specific containerif required. Access to a given container is made possible by providingrelatively complicated hoisting mechanisms which can be used to stackand remove given containers from stacks. The cost of such systems are,however, impractical in many situations and they have mainly beencommercialised for the storage and handling of large shippingcontainers.

The concept of using freestanding stacks of containers and providing amechanism to retrieve and store specific containers has been developedfurther, for example as described in EP 0 767 113 B to Cimcorp. ′113discloses a mechanism for removing a plurality of stacked containers,using a robotic load handler in the form of a rectangular tube which islowered around the stack of containers, and which is configured to beable to grip a container at any level in the stack. In this way, severalcontainers can be lifted at once from a stack. The movable tube can beused to move several containers from the top of one stack to the top ofanother stack, or to move containers from a stack to an externallocation and vice versa. Such systems can be particularly useful whereall of the containers in a single stack contain the same product (knownas a single-product stack).

In the system described in ′113, the height of the tube has to be asleast as high as the height of the largest stack of containers, so thatthat the highest stack of containers can be extracted in a singleoperation. Accordingly, when used in an enclosed space such as awarehouse, the maximum height of the stacks is restricted by the need toaccommodate the tube of the load handler.

EP 1037828 B1 (Autostore) the contents of which are incorporated hereinby reference, describes a system in which stacks of containers arearranged within a frame structure. A system of this type is illustratedschematically in FIGS. 1 to 4 of the accompanying drawings. Robotic loadhandling devices can be controllably moved around the stack on a systemof tracks on the upper most surface of the stack.

Other forms of robotic load handling device are further described in,for example, Norwegian patent number 317366, the contents of which areincorporated herein by reference. FIGS. 3(a) and 3(b) are schematicperspective views of a load handling device from the rear and front,respectively, and FIG. 3(c) is a schematic front perspective view of aload handling device lifting a bin.

A further development of load handling device is described in UK PatentApplication No. GB1314313.6— Ocado Innovation Limited—where each roboticload handler only covers one grid space, thus allowing higher density ofload handlers and thus higher throughput of a given size system.However, any suitable form of load handling device may be used.

In the known robotic picking systems described above, robotic loadhandling devices are controllably moved around the top of the stacks ona track system forming a grid. A given load handling device lifts a binfrom the stack, the container being lifter containing inventory itemsneeded to fulfil a customer order. The container is carried to a pickstation where the required inventory item may be manually removed fromthe bin and placed in a delivery container, the delivery containerforming part of the customer order, and being manually filled fordispatch at the appropriate time. At the pick station, the items mayalso be picked by industrial robots, suitable for such work, for exampleas described in UK Patent Application No GB1502123.1— Ocado InnovationLimited.

It will be appreciated that this picking of inventory items from storagebins in to delivery containers can cause delays at pick stations,causing congestion at the pick stations and delays in the assembly ofcustomer orders. In addition, the pick stations themselves represent asignificant investment, whether design for manual or robotic picking.

BRIEF SUMMARY

According to the invention there is provided a picking system for astorage system, the storage system comprising: a first set of parallelrails or tracks and a second set of parallel rails or tracks extendingsubstantially perpendicularly to the first set in a substantiallyhorizontal plane to form a grid pattern comprising a plurality of gridspaces; a set of uprights, the uprights supporting the tracks, theuprights and tracks together defining a framework; and a plurality ofcontainers located beneath the tracks and within the framework, aportion of the containers occupying a space below a grid space;characterised in that the storage system further comprises: pickingmeans disposed above the containers; in which at least one containercomprising inventory items, the picking means being adapted to pick atleast one inventory item from the at least one container and deposit theor each item into at least one or more further containers.

According to the invention there is further provided a method of pickinginventory items from a storage system, the storage system comprising afirst set of parallel rails or tracks and a second set of parallel railsor tracks extending substantially perpendicularly to the first set in asubstantially horizontal plane to form a grid pattern comprising aplurality of grid spaces; a set of uprights, the uprights supporting thetracks, the uprights and tracks together defining a framework; aplurality of containers located beneath the tracks and within theframework, each container occupying a space below a grid space; themethod comprising the steps of: locating at least one first containercomprising a target inventory item to be picked; locating at least onesecond container in which the target inventory item is to be deposited;transferring at least one item from the at least one first container tothe at least one second container; in which the item being transferreddirectly from the said at least one first container to the said at leastone second container by picking means located on or above the grid.

In this way, parts of customer orders, or some or all customer ordersmay be picked robotically directly on the grid. This reduces the amountof manual intervention required in the system which improves efficiencyand reduces costs.

In this way, the present invention overcomes the problems of the priorart and provides a system and method of increasing the speed at whichcustomer orders are compiled and reduce the overall cost and improve theefficiency of large bin handling storage and picking systems.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with reference to the accompanyingdiagrammatic drawings in which:

FIG. 1 is a schematic, perspective view of a frame structure for housinga plurality of stacks of bins in a storage system;

FIG. 2 is a schematic, plan view of part of the frame structure of FIG.1 ;

FIGS. 3(a) and 3(b) are schematic, perspective views, from the rear andfront respectively, of one form of robotic load handling device for usewith the frame structure of FIGS. 1 and 2 , and FIG. 3(c) is a schematicperspective view of the known load handler device in use lifting a bin;

FIG. 4 is a schematic, perspective view of a known storage systemcomprising a plurality of load handler devices of the type shown inFIGS. 3(a), 3(b) and 3(c), installed on the frame structure of FIGS. 1and 2 , together with a robotic load handling device in accordance withone form of the invention.

FIG. 5 is a schematic, perspective view of one form of robotic pickingarea in accordance with one aspect of the invention the robotic pickingarea being located above a dispatch dock, the picking area comprising aseries of grids forming tracks above a plurality of delivery containers;

FIG. 6 a is a schematic, cut-away, perspective view of one form ofrobotic picking device in accordance with a first embodiment of theinvention, the robotic picking device picking an inventory item 28 froma bin located in the robotic picking area of FIG. 5 ;

FIG. 6 b is a schematic, cut-away, perspective view of one form ofrobotic picking device in accordance with a first embodiment of theinvention, the robotic picking device depositing the picked item fromFIG. 6 a in a delivery container located in the robotic picking area ofFIG. 5 , the delivery container being pre-loaded with delivery bags;

FIG. 7 is a schematic, perspective view of a robotic picking device inaccordance with a first embodiment of the invention, picking aninventory item from a bin in a stack within the main storage system;

FIG. 8 a is a schematic, cut-away, perspective view of a robotic pickingdevice in accordance with a further invention, the robotic pickingdevice being adapted to lift a bin containing inventory items from thestorage system, pick an inventory item from the bin and deposit thepicked item in to a delivery container, the delivery container being ina dispatch portion of the grid, a robotic picking area or within thestorage system;

FIGS. 8 b to 8 f are cut-away, schematic views of the dispatch portionof FIG. 8 , showing the robotic picking device of FIG. 8 a depositing aninventory item robotically picked from the storage system directly in toa delivery bin;

FIGS. 8 g to 8 i are cut-away, schematic views of a portion of thestorage system of FIG. 5 , showing the robotic picking device of FIG. 8a picking inventory items from bins within the grid and depositing themwith a delivery container held within the body of the robotic pickingdevice;

FIGS. 9 a to 9 f are cut-away perspective, schematic views of a roboticpicking device in accordance with a further aspect of the invention, therobotic picking device being adapted to receive a bin containinginventory items from the storage system, pick an inventory item from thebin and deposit the picked item in to a delivery container, the deliverycontainer being in a dispatch portion of the grid, a robotic pickingarea of the grid or within the storage system;

FIG. 10 a is a schematic, perspective view of a further form of roboticdevice, in accordance with the invention, the robotic device comprisingan opening in the top surface of the vehicle body, thereby extending acavity through the robotic device, the extended cavity enabling thecontent of the bin or delivery container to be accessed through the topof the device;

FIG. 10 b is a schematic, perspective view of the robotic device of FIG.10 a showing a delivery container in situ in the extended cavity;

FIG. 10 c is a schematic, perspective view of the robotic device ofFIGS. 10 a and 10 b on the grid of the storage system, the systemfurther comprising robotic picking means adapted so as to access thecontent of the delivery container or bin located within the cavity ofthe robotic device, the robotic picking means picking an inventory itemfrom one of a number of robotic devices located on the grid of thestorage system;

FIG. 10 d is a schematic, perspective view of the robotic device ofFIGS. 10 a and 10 b on the grid of the storage system, the systemfurther comprising robotic picking means adapted so as to be carried ona further form of robotic device, the robotic picking means picking aninventory item from one of a number of robotic devices located on thegrid of the storage system and placing said inventory item in a roboticdevice comprising a delivery container;

FIGS. 11 a and 11 b are schematic, perspective views of a roboticpicking device in accordance with a further aspect of the invention, therobotic picking device being moveably mounted on an edge of the storagesystem, the robotic picking device picking an inventory item from withina portion of the storage system of FIG. 5 and depositing the inventoryitem within a delivery container located in the storage system;

FIGS. 12 a and 12 b are schematic, perspective views of a roboticpicking device in accordance with a further aspect of the invention, therobotic picking device being moveably mounted above the storage system,the robotic picking device being movable to positions above any storagebin or delivery container within the storage system, the robotic pickingdevice being adapted so as to pick inventory items directly from atleast one storage bin and deposit the or each item in at least onedelivery container;

FIGS. 13 a, 13 b and 13 c are perspective, schematic cut-away views of abin in accordance with a further invention, the bin comprising a numberof dispenser mechanisms capable of automatically and under remotecontrol, depositing items from the bin in to delivery containers;

FIG. 13 d is a schematic, perspective view of a robotic handling devicein accordance with a further invention, the robotic handling devicecomprising means for lifting and carrying the bin of FIGS. 13 a, b and cthe bin dispensing inventory items contained therein, in to deliverycontainers located in a portion of the storage system;

FIGS. 14 a, 14 b and 14 c are schematic views of further aspects of aninvention showing a bin comprising a mechanism for withdrawing a basesection of the bin, the base section moving between a first and secondposition such that in the first position an inventory item is heldwithin the bin, and in the second position the inventory item isreleased from the bin;

FIG. 14 d is a schematic view of one form of mechanism for moving thebase section of the bin of FIGS. 14 a, b , and c from the first positionto the second position;

FIG. 14 e is a schematic, cut away view of a further form of robotichandling device carrying a bin, the bin comprising a base movable from afirst closed position to a second open position, showing an inventoryitem having dropped from the bin to a delivery container on movement ofthe base of the bin in to the second open position;

FIG. 15 a is a schematic view of a further form of bin having a basesection that is movable from a first to a second position, the binhaving a base comprising a plurality of portions independently movablefrom first to second positions in order to allow inventory items locatedwithin said bin to be controllably deposited in to a specific part of adelivery container;

FIG. 15 b is a schematic, cut-away view of a further form of roboticload handling device in accordance with one form of the invention, theload handling device carrying the bin of FIG. 15 a showing the inventoryitem being deposited in to a given bagged part of a delivery containerbelow;

FIG. 16 a is a schematic view of a further bin in accordance with afurther aspect of the invention, the bin comprising an alternativeembodiment of mechanism for moving the base section of the bin from afirst position to a second position such that an inventory item heldwithin the bin may fall into the delivery container below;

FIG. 16 b is a schematic, cut-away view of a further form of roboticload handling device in accordance with one form of the invention, theload handling device carrying the bin of FIG. 16 a showing the inventoryitem being deposited in a delivery container below;

FIG. 17 is a schematic view of a further bin in accordance with afurther aspect of the invention, the bin comprising an alternativeembodiment of mechanism moving the base section of the bin from a firstposition to a second position such that an inventory item held withinthe bin falls into the delivery container below;

FIG. 18 a is a schematic view of a bin in accordance with a furtheraspect of the invention, the bin comprising an alternative mechanism fordepositing inventory items located within the storage container to bedeposited in to a delivery container below, the inventory item being ofthe flowing type; and

FIG. 18 b is a schematic cut-away view of a further form of robotic loadhandling device in accordance with one form of the invention, the loadhandling device carrying the bin of FIG. 18 a showing the inventoryitems being deposited in a delivery container below.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2 , stackable storage containers, known as bins10, are stacked on top of one another to form stacks 12. The stacks 12are arranged in a frame structure 14 in a warehousing or manufacturingenvironment. FIG. 1 is a schematic perspective view of the framestructure 14, and FIG. 2 is a top-down view showing a single stack 12 ofbins 10 arranged within the frame structure 14. Each bin 10 typicallyholds a plurality of product or inventory items 28, and the inventoryitems within a bin 10 may be identical, or may be of different producttypes depending on the application. Furthermore, the bins 10 may bephysically subdivided to accommodate a plurality of different inventoryitems 28.

In the description below, bins 10 will be used to denote containersintended for the storage of inventory items 28, whilst deliverycontainers DT will be used to denote containers intended to be filled tofulfil customer orders placed by customers. It will be appreciated thatthis terminology is used for ease of reference and explanation withinthis document. However, it should be noted that the bins 10 and thecontainers DT may be of the same shape and configuration. Furthermore,delivery containers DT may be stored in bins 10 within the storagesystem or any part thereof.

The frame structure 14 comprises a plurality of upright members 16 thatsupport horizontal members 18, 20. A first set of parallel horizontalmembers 18 is arranged perpendicularly to a second set of parallelhorizontal members 20 to form a plurality of horizontal grid structuressupported by the upright members 16. The members 16, 18, 20 aretypically manufactured from metal. The bins 10 are stacked between themembers 16, 18, 20 of the frame structure 14, so that the framestructure 14 guards against horizontal movement of the stacks 12 of bins10, and guides vertical movement of the bins 10.

The top level of the frame structure 14 includes rails 22 arranged in agrid pattern across the top of the stacks 12. Referring additionally toFIGS. 3 a-3 c and 4, the rails 22 support a plurality of robotic loadhandling devices 30. A first set 22 a of parallel rails 22 guidemovement of the load handling devices 30 in a first direction (X) acrossthe top of the frame structure 14, and a second set 22 b of parallelrails 22, arranged perpendicular to the first set 22 a, guide movementof the load handling devices 30 in a second direction (Y), perpendicularto the first direction. In this way, the rails 22 allow movement of theload handling devices 30 in two dimensions in the X-Y plane, so that aload handling device 30 can be moved into position above any of thestacks 12.

Each load handling device 30 comprises a vehicle 32 which is arranged totravel in the X and Y directions on the rails 22 of the frame structure14, above the stacks 12. A first set of wheels 34, consisting of a pairof wheels 34 on the front of the vehicle 32 and a pair of wheels 34 onthe back of the vehicle 32, are arranged to engage with two adjacentrails of the first set 22 a of rails 22. Similarly, a second set ofwheels 36, consisting of a pair of wheels 36 on each side of the vehicle32, are arranged to engage with two adjacent rails of the second set 22b of rails 22. Each set of wheels 34, 36 can be lifted and lowered, sothat either the first set of wheels 34 or the second set of wheels 36 isengaged with the respective set of rails 22 a, 22 b at any one time.

When the first set of wheels 34 is engaged with the first set of rails22 a and the second set of wheels 36 are lifted clear from the rails 22,the wheels 34 can be driven, by way of a drive mechanism (not shown)housed in the vehicle 32, to move the load handling device 30 in the Xdirection. To move the load handling device 30 in the Y direction, thefirst set of wheels 34 are lifted clear of the rails 22, and the secondset of wheels 36 are lowered into engagement with the second set ofrails 22 a. The drive mechanism can then be used to drive the second setof wheels 36 to achieve movement in the Y direction.

In this way, one or more robotic load handling devices 30 can movearound the top surface of the stacks 12 on the frame structure 14, asshown in FIG. 4 under the control of a centralised control utility (notshown). Each robotic load handling device 30 is provided with liftingmeans 38 for lifting one or more bins 10 from the stack 12 to access therequired products.

The body of the vehicle 32 comprises a cavity 40, the cavity 40 being ofa size capable of holding a bin 10. The lifting means 38 comprises winchmeans and a bin gripper assembly 39. The lifting means lifts a bin 10from the stack 12 to within the cavity 40 within the body of the vehicle32.

In this way, multiple products can be accessed from multiple locationsin the grid and stacks at any one time.

The robotic load handling devices 30 remove bins 10 containing inventoryitems 28 (not shown) therein and transport the bins 10 to pickingstations (not shown) where the required inventory items 28 are removedfrom the bins 10 and placed into bins 10 comprising delivery containersDT. It is important to note that a delivery container DT may fit withina bin 10. The bins 10 may comprise inventory items 28 or may comprisedelivery containers DT. Furthermore, the delivery containers DT maycomprise at least one bag 52, the inventory items 28 being pickeddirectly in to a bag 52 at a pick station (not shown).

The empty bins 10 or the bins comprising delivery containers DT or thebins comprising delivery containers DT and bags 52 may all be storedwithin the stacks 12. It will be appreciated that all the bins 10 havesubstantially the same external shape and configuration.

FIG. 4 shows a typical storage system as described above, the systemhaving a plurality of load handling devices 30 active on the grid abovethe stacks 12.

FIGS. 1 and 4 show the bins 10 in stacks 12 within the storage system.It will be appreciated that there may be a large number of bins 10 inany given storage system and that many different items 28 may be storedin the bins 10 in the stacks 12, each bin 10 may contain differentcategories of inventory items 28 within a single stack 12.

In one system described above and further in UK Patent ApplicationNumber GB1410441.8— Ocado Innovation Limited, hereby incorporated byreference, the storage system comprises a series of bins 10 that mayfurther comprise delivery containers DT with customer orders containedtherein or may further comprise bins 10 with inventory items 28 awaitingpicking contained therein. These different bins 10 and combinationsthereof may be contained in the storage system and be accessed by therobotic load handling devices 30 as described above.

In a first aspect of the invention, the robotic picking and storagesystem described above, with reference to FIGS. 1 to 4 , comprises arobotic picking system, apparatus, and method to enable inventory items28 to be picked on the storage system described above, thereby avoidingbins 10 being transferred to pick stations for manual or robotic pickingof inventory items 28 in to customer orders.

As shown in FIG. 5 , a portion of the storage system 100 may be setaside for the express purpose of robotic on grid picking. Any such areawill comprise delivery containers DT located beneath the dedicatedportion of grid, which may be remotely located from, but linked to themain portion of the framework 14 and grid 22 system by an extension ofthe grid 22, on which the robotic load handlers 30 operate. The portion100 of the grid 22 may act as a dedicated robotic picking area. However,it will be appreciated that the main storage system may be used in themanner described below, as long as at least some delivery containers DTare located at the top of at least some of the stacks 12 of bins 10.

A plurality of robotic handling devices 30, for instance as describedabove and in UK Patent Application No. GB1413155.1— Ocado InnovationLimited, hereby incorporated by reference, are operative on the grid 22system and under control of a separate centralised control utility asdescribed in UK Patent Application No. GB1509613.4— Ocado InnovationLimited, hereby incorporated by reference.

In addition to the robotic load handling devices 30 there are, accordingto the present invention, a plurality of additional, similarly lookingrobotic picking devices 130 which may be used to pick inventory items 28from bins 10 and to deposit items directly in the delivery containersDT.

As shown in FIG. 6 a , one form of a robotic picking device 130 inaccordance with one aspect of the invention, comprises robotic pickingmeans 50 within the cavity 40 of the body of the load handling device30. The external shape and configuration of the device 130 substantiallymatches that of the load handling device 30 such that it may operate onthe grid 22 in the same manner. However, it will be appreciated, that inthis form of robotic picking device 130, the picking means 50 takes thespace previously used for the location of the bin 10 being lifted from astack 12. As described below, the purpose of the robotic picking device130 is different to that of the load handling device 30.

In one aspect of the present invention, a robotic load handling device30 is remotely instructed by a centralised control utility (not shown)to collect a bin 10 from a stack 12 in the main storage system, the bin10 containing inventory items 28 required for a customer order. The loadhandling device 30 deposits the bin 10 containing inventory items 28required for the customer order, in a vacant position in the roboticpicking portion 100 or any other suitable position in beneath the grid22 of the storage system. A robotic picking device 130 is positionedabove the deposited bin 10, containing inventory items 28, by thecentralised utility. Under remote control from the centralised utility,potentially assisted by on-board sensors, cameras and processing means,the robotic picking means 50 located within the cavity 40 of the pickingdevice 130 is instructed to pick at least one inventory item 28 from thebin 10. The item picked is withdrawn in to the cavity 40 of the roboticpicking device 130. The picking device 130 is then moved to a positionon the robotic picking portion of the system or any other part of thestorage system above a delivery container DT. The delivery container DTmay comprise a number of bags 52 in which the inventory item 28 may beplaced. Alternatively, the delivery container DT may comprise an emptydelivery container DT. The robotic picking device 130 places theinventory item 28 in the delivery container DT or a bin 10 comprising adelivery container DT contained therein.

It will be appreciated that the delivery container DT may alreadycomprise inventory items 28 either previously picked robotically ormanually on grid, or at pick stations, or picked manually at pickstations. It will be appreciated that the delivery container DTassociated with a given customer order may be filled via many separatepicking steps across a period of time. Furthermore, a customer order maycomprise multiple delivery containers DT, therefore a delivery containerDT in the picking portion of the system 100 may comprise only part of acustomer order. Multiple delivery containers DT may be consolidated at adispatch location immediately prior to the order being loaded on to avehicle for delivery.

It will also be appreciated that this form of robotic picking device 130substantially occupies a single grid space on the horizontal grid 22 ofthe framework 14. However, other forms of robotic picker device 130 mayoccupy more grid spaces. For example, a robotic picking device 130 mayoccupy 2×1 grid spaces or 2×2 grid spaces or more as required to performthe function described.

Furthermore, the robotic picking device 130 may comprise picking means50 of a different form to that shown in FIGS. 6 a-6 b and 7. Anysuitable form of remotely controllable or autonomously capable pickingmeans 50 may be used. It will be appreciated that the picking means 50may have different grippers or hands to pick inventory items 28 frombins 10. For example, hands (not shown) may comprise suction cupsactivated by vacuum means or may comprise remotely controllable grippersactivated by the central control utility.

Using the robotic picking device 130, comprising the picking means 50,removes the requirement to transport a bin 10 from a stack 12 to a pickstation (not shown) and remove the required inventory item 28 and placeit in an allocated delivery container DT.

In a further aspect of the invention, with reference to FIGS. 6 a and 6b , the robotic load handling device 130 may comprise a robotic pickerdevices 130 as shown in FIG. 6 a . Such a robotic picker device 130 maybe provided with picking means 50 within the cavity 40 of the body ofthe device 130. The picking means may comprise a robotic arm capable ofremote or autonomous manipulation such that inventory items 28 may bepicked from bins 10 or delivery containers DT and deposited in bins 10or delivery containers DT.

In use, and as shown in FIGS. 6 a and 6 b such a robotic picker device130 would be positioned above a bin 10 transported to or located in thepicking portion of the storage system. The device 130 would be used torapidly pick inventory items 28 from bins 10 and deposit the inventoryitems 28 in the delivery containers DT located adjacent the bins 10. Asshown in FIGS. 6 a and 6 b it is possible for inventory items 28 to bepicked from bins 10 and deposited in delivery containers with relativelylittle movement of the picking device 130.

Using this method, it would also be possible to consolidate customerorders in delivery containers DT located in the picking portion of thegrid. For example, the robotic picker device 130 may be positioned overa first delivery container DT1 and the picking means 48 remotelyactivated to pick up an inventory item from the delivery container DT1.The robotic picker device 130 may then be moved in to position over asecond delivery container DT2 and the picking device activated to placethe in to the second delivery container DT2. This will be particularlyrelevant to customer orders where bulky items may have beeninefficiently stored in delivery containers DT and can be moved aroundin order to provide a more efficient packing regime for a given order.

In this aspect of the invention, the use of robotic load handlers in themanner described in, for example, UK Patent Application No GB1410127.3may be envisaged, and such load handling devices are hereby incorporatedby reference.

This is advantageous as the delivery containers DT are packed in todelivery vans for onward delivery to customers, therefore the moreefficiently the containers DT are packed, the more efficiently the vansmay be packed.

In the above ways, it will be appreciated that it is beneficial to pickpopular items from one bin 10 in to multiple delivery containers DT.Using robotic picker devices 330, reduces congestion at manual pickstations, increases throughput and reduces costs.

In further aspects of the invention, the robotic picking and storagesystem described above with reference to FIGS. 1 to 4 comprisesdifferent forms of robotic picking devices 130, 230, 330, 430

As explained with reference to FIGS. 1 to 7 , the robotic load handlingdevices 30 described above act co-operatively, under the control of asuitable centralised control utility, to remove bins 10 from the stacks12 of the storage system. The function of each robotic handling device30 is to collect and transport a bin 10 containing the requiredinventory item 28 or items to a pick station from where the requiredinventory item 28 or items are loaded in to a delivery container DT. Itwill be appreciated that robotic load handling devices 30 may haveadditional functions such as removing bins 10 from stacks 12 and movingsaid bins 10 to alternative locations within the stacks 12 of bins 10,as well as periodically rearranging the bins 10 in the stacks 12 in aform of housekeeping task.

In a further aspect of the invention another derivative of a roboticload handling device 230 may be provided with alternative picking means150 within the body of the device 230, which can be used for picking andlifting an inventory item 28 directly from a storage bin 10, locatedwithin the stacks 12, in the main portion of the storage system andtransferring the inventory item 28 directly to a delivery container DT.

The alternative form of robotic picking device 230 is shown in FIG. 8 a. The picking device 230 in the following example comprises a 2×1 gridspacing device. However, it will be appreciated that devices 230 ofalternative sizes may be envisaged.

As can be seen in FIG. 8 a , the picking device 230 comprises a cavity40, lifting means, a bin gripper assembly 39 and picking means 150. Thelifting means together with the bin gripper assembly 39 act so as toreleasably attach to a bin 10 to enable the bin 10 to be lifted from thestack 12 by the robotic picking device 230, in a similar manner to thatdescribed with reference to FIGS. 3 a-3 c . The lifting means may takethe form of a torpedo engageable with co-operating portions of the bins10 to enable the lifting means to pick the bin 10 from a stack 12. Itwill be appreciated that any suitable form of lifting means 44 may beused that enables the robotic picking device 230 to engage a bin andthen raise it from its position in the stack 12 or in the picking areaof the system. The bin 10 is retained in the cavity 40 by suitableretaining means movable from a first position, to allow the liftingmeans and the bin gripper assembly 39 to withdraw the bin 10 in to thecavity 40, to a second position where the bin 10 is held in situ in thecavity 40 of the device 230.

The picking means 150 acts so as to pick inventory items from the bin 10lifted in to the cavity 40 within the picking device 230. The pickingdevice 230 further comprises moving means 48 for sliding the bin 10 froma first position where it is located after lifting, to a second positionwhere it is located beneath the picking means 150. It will beappreciated that the moving means 48 may additionally act to retain thebin 10 in the cavity 40.

In use, the lifting means 44 of the picking device 230 is placed over abin 10 in a stack 12 or in a picking area. The lifting means 44 and bingripper assembly 39 together lift the bin 10 in to the cavity 40 of thedevice 230, as shown in FIGS. 8 c and 8 d . Once lifted, the bin 10 istransferred by the moving means 48 from the first, lifted position tothe adjacent second position within the cavity 40 as shown in FIG. 8 e .It should be noted that the first position substantially corresponds toa first grid square 22 in the horizontal part of the framework 14 andthe second position substantially corresponds to a second grid square22′ adjacent the first grid square 22.

The picking means 150 is disposed above the second position within thecavity 40 of the device 230. The picking means 150 comprises a suitablegrabbing means for locating and engaging at least one inventory item 28from the bin 10 as shown in FIG. 9 d . It will be appreciated that thepicking means 150 comprises means for engaging inventory items 28 ofnumerous shapes and sizes. Indeed, different engaging means may berequired for different inventory items 28 to be picked. Furthermore, thepicking means 150 is required to be movable in at least x-y-zdirections.

As shown in FIG. 8 f , once an inventory item is engaged by the pickingmeans 150, the bin 10 is moved from the second position to the firstposition by the moving means 48. The inventory item 28 is retained onthe picking means 150. The robotic picking device 230 is then moved to aposition such that the second position within the device is above atarget delivery container DT. The picking means 150 is then extendedtoward the delivery container DT identified as requiring the inventoryitem picked, as required, depending on the size and shape of theinventory item.

Once picked, the inventory item is placed in a delivery container DT,shown in FIG. 8 f are positioned beneath the cavity 40 in the second ofthe two grid spaces occupied by the picking device 230. However, it willbe appreciated that the robotic picking device 230 may be moved suchthat the picking device 230 is disposed above an alternative deliverycontainer DT in the robotic picking area 100 or on the main storagesystem.

FIGS. 8 g, 8 h and 8 i show an alternative method of robotic, on gridpicking in which the delivery container DT is lifted by the roboticpicking device 230 in to the cavity 40, the inventory items 28 beingdisposed within bins 10 within the robotic picking area or in the mainsystem.

In this alternative embodiment it will be appreciated that the roboticpicking device 230 may travel on the grid 22 carrying the deliverycontainer DT, the picking means 150 being used to pick inventory itemsfrom bins 10 within the storage system. In this way, multiple inventoryitems may be picked in to a single delivery container DT being carriedby a single robotic picking device 230.

It will be appreciated that such robotic picker devices 230 may be usedto retrieve a bin 10 from the main storage system in which the requiredinventory items 28 were located. Alternatively, load handling devices 30may be used to lift bins 10 from the main storage system and transportthem to a dedicated robotic picking area 100 of the system, thededicated picking area 100 having only a single layer of bins 10 ordelivery containers DT disposed within the framework 14.

The picker device 230 would, under remote control from the centralisedcontrol utility, potentially assisted by on-board sensors camera andprocessing means, be positioned above the bin 10 deposited by therobotic load handling device 30 and act as described above withreference to FIGS. 8 g, 8 h and 8 i . Inventory items 28 picked beingdeposited in target delivery containers DT in the dedicated portion 100of the storage system. It will be appreciated that means to identify thecorrect delivery container DT and as appropriate the correct positionwithin the delivery container DT, is provided on the picking device 230if necessary, using remotely controlled automatic positioning means. Inthis way, the inventory item 28 is robotically picked from a bin 10 anddeposited in a delivery container DT without the need for any bins 10 ordelivery containers DT to be transported to picking stations.

It will be appreciated that the robotic picker handling device 230 maybe of any size capable of carrying a bin 10 whilst also containingpicking means 150. This may be achievable with regard to the device 230if the device 230 was adapted to have limited winch capabilities withrespect to other robotic load handling devices 30 operating on thestorage system. In this specific example, it may be that the pickerhandling device 230 need only be provided with telescopic grippers ontwo sides of the cavity within the body of the device 230.

Given the limited space within the robotic picking device 230 analternative robotic picking device 430 is shown in FIGS. 9 a to 9 f . Inthis robotic picking device 430 the bin 10 is not lifted in to thecavity 40 of the device 430 by lifting means 44 and bin gripper assembly39 rather the bin 10 is pushed up in to the cavity 40 by raising means46 located in the base of the storage system. The raising means 46occupies a grid space as shown in FIG. 9 c , for example.

The raising means 46 comprises a substantially flat plate havinglocating pins 47 for co-operating with suitable co-operating means onthe underside of the or each bin 10 in order to stabilise the bin 10 onlifting. The raising means 46 may be raised by any suitable means, forexample via hydraulically activated pistons extending in a telescopicmanner upwardly toward the grid.

In use, as shown in FIGS. 9 b to 9 f , a robotic load handling device 30(not shown in FIG. 9 b ) retrieves a bin 10 from the storage system anddeposits said bin 10 on the raising means 46. A robotic picking device430 is moved in to position over the bin 10 on the raising means 46. Theraising means 46 is activated, for example by the centralised controlutility, and the bin 10 is raised in to the cavity 40 of the device 430.The device 430 comprises releasable latching means 49 that act so as toretain the bin 10 within the cavity 40 during the picking process. Thelatching means 49 may comprise movable arms that locate beneath the bin10, once the bin 10 is in situ. Alternatively the latching means 49 maycomprise electromagnetic catches operable by solenoids or any othersuitable means. It will be appreciated that any number of releasablelatching mechanisms may be used performing the required function ofretaining the bin 10 in the cavity 40.

Once the bin 10 is in situ, the picking means 150 may be used in amanner similar to that described above with reference to the previousrobotic picking device 230. Namely, the picking means 150, movable inx-y-z directions is manipulated in to position above an inventory item28 in the bin 10 under the control of the central control utility or anyother suitable control means. The picking means 150 is then lowereddownwardly and engages an inventory item 28. It will be appreciated thatthe picking means 150 is provided with suitable gripping means to engagewith an inventory item 28. Once engaged, the picking means 150 is liftedupwardly and moved in to position above a delivery container DT locatedbeneath the grid space adjacent the raised bin 10.

Once the picking means 150 is in the correct location above the requireddelivery container DT, assisted by sensor or camera means asappropriate, the inventory item 28 is either released in to the deliverycontainer DT or placed by movement in the z-axis of the picking means150 in to the delivery container DT.

It will be appreciated that the raising means 46 may be used to raise adelivery container DT in to the cavity 40 within the picking device 430and the picking means 150 used to pick inventory items 28 from bins 10located underneath the grid and place said inventory items in thedelivery container DT within the cavity 40 of the picking device 430.

Once all the required picking steps are complete, the robotic pickingdevice 430 returns to the grid square above the raising means 46, theraising means 46 is raised, the bin 10 or the delivery container DT isunlatched from the device 430 and lowered beneath the grid space. Thebin 10 or delivery container DT is then positioned in the required placeby a load handling device 30 where it awaits its next action.

FIGS. 10 a to 10 d show a further embodiment of a robotic device 30. Ascan be seen in FIG. 10 a , the robotic device 330 comprises a cavity 40that extends through the body of the robotic device 330. In order toachieve this, the lifting means 44, bin gripping mechanism 39 and allother mechanics and electronics required to operate the robotic device330 have been moved to the sides of the device 330, creating a roboticdevice having overhanging sections. It will be appreciated that theoverhanging sections shown in FIGS. 10 a and 10 b are exemplaryembodiments only and there may be only one overhanging section disposedon one side of the robotic device. However, it should be noted that thecross-sectional area defined by the wheels of the device 330 occupy asingle space of the grid 22 only.

In use, a bin 10 or a delivery container DT may be lifted from thestorage system in to the extended cavity 40 of the device 330. As shownin FIG. 10 b , when in situ the delivery container DT, in this example,is exposed at the top surface of the device 330. Therefore, it ispossible for inventory items to be picked directly in to the deliverycontainer DT.

It will be appreciated that there are many ways of picking inventoryitems directly in to the delivery container DT and FIGS. 10 c and 10 dshown two ways in which items may be picked directly in to the device330 of FIGS. 10 a and 10 b.

In the embodiment of FIG. 10 c , robotic picking means 250 is suspendedabove the storage system. A number of robotic devices 330 containingbins 10 comprising inventory items 28 required to fulfil customer ordersare positioned within reach of the picking means 250. The picking means250 may efficiently pick from the bins 10 located in the devices 330directly in to the delivery container DT located in the central roboticdevice 330.

It will be appreciated that if the robotic picking means 250 hassufficient reach, inventory items 28 may be picked directly from thebins 10 located beneath the grid 22 of the storage system. Furthermore,in this example it will be appreciated that the picking means 250 may besuspended at a fixed point from the ceiling above the storage system. Itwill be appreciated that multiple picking means 250 may be suspendedfrom the ceiling above the storage system.

Alternatively, a single picking means 250 may be located on a moveablebeam moveable in the X-Y direction above the storage system in orderthat the single picking means 250 may be moved to required points abovethe storage system under the control of a centralised control utility.

It will further be appreciated that robotic picking means 250 may bepositioned around the edges of the storage system to allow for pickingat the extremes of the system.

In the embodiment of FIG. 10 d a further robotic picking device 550 isshown picking goods directly from one robotic device 330 comprising abin 10 in to a robotic device 330 comprising a delivery container DT.The robotic picking device 550 is mounted on a form of robotic loadhandling device 630. It will be appreciated that the device 630 does nothave the ability to handle bins 10 or delivery containers DT and is morea means for moving picking means 550 around the grid 22 above thestorage system to a position where picking can take place. It will befurther appreciated that the robotic picking device 550 mounted on therobotic load handling device 630 may be moved around the grid and beused to pick inventory items from bins 10 in all locations, as long asthe inventory items 28 are accessible to the picking means. For example,in one example, a bin 10, may be lifted from one of the stacks 12 in thesystem and releasably latched such that it is disposed above the levelof the grid. A mobile robotic picking device may then pick a number ofinventory items 28 as required and deposit them individually or incombination in to a target delivery container DT. The bin 10 may then bereturned to an appropriate stack 12. The latching means supporting thebin 10 on the grid 22 may be of any suitable form capable of supportingthe bin 10 on the grid 22 and may be remotely operable. The overhangingportion section of the robotic device constitutes a complementaryportion 81 that corresponds to a complementary portion 80 formed on therobotic picking device. The complementary portions 80, 81 are configuredto be engaged when the robotic picking device is in a position todeposit inventory items into the at least one delivery container.

It will be appreciated that the advantage of this aspect of theinvention is that the bins 10 and delivery containers DT are lifted fromthe stacks 12 once and retained in the robotic devices 330. The bins 10and delivery containers DT do not need to be picked up from one locationand temporarily placed at an appropriate point of the system whilstpicking occurs. In this embodiment it is possible for the centralisedcontrol utility to position the bins 10 and the delivery containers DTwithin the devices 330 in a relatively uncongested part of the system.In this way the grid 22 may be used to its fullest capacity.

It will be appreciated in the case of all the robotic picking devicesdescribed above, the picking means 50, 150, 250, 350, 450, 550 and 650have been described as picking single inventory items 28 from a bin andplacing it in a delivery container DT. However, in a further aspect ofthe invention the picking means 50, 150, 250, 350, 450, 550 and 650 maybe adapted to pick multiple inventory items 28, either multipleinventory items 28 from a single bin 10 or single items 28 from multiplebins 10. The multiple inventory items 28 picked may be for the samedestination delivery container DT or may be for multiple deliverycontainers DT.

In order that the picking means 15 may pick multiple items from a singlebin 10, it will be appreciated that the robotic picking devicesdescribed above may be provided with storage means within the cavity 40of the device.

In use, a robotic picking device as described above is moved in toposition above a bin 10 containing inventory items 28 to be picked. Inthe situation where a single customer has ordered a plurality of asingle inventory item 28, the picking means 150 picks the first item 28and places said item 28 in the storage means within the cavity 40. Thepicking means 150 is then manipulated to pick a further inventory item28 and places said second inventory item 28 in the storage means withinthe cavity 40 of the device. This is repeated until all the requiredinventory items 28 are in the storage means. The robotic picking devicethen moves in to position above the delivery container DT beneath thegrid and the picking means used to move the items 28 from the storagemeans to the delivery container DT, placing the items as required,assisted by suitable sensor means or camera means as required.

In the case where several inventory items 28′, 28″ and 28′″ of differentcategories located in a number of bins 10, the robotic picking device ismoved in to position above the first bin 10′ and the first inventoryitem 28′ is picked by the picking means and placed in the storage meanswithin the cavity 40 of the device. The robotic picking device is thenmoved to a second bin 10″ where the second inventory item 28″ is stored.The second item 28″ is then picked by the picking means and placed inthe storage means in the cavity 40 of the device. Finally the device ismoved in to position over the third bin 10′″ and the third item 28′″ ispicked. The robotic picking device is then moved in to position over thetarget delivery container and the items 28′, 28″ and 28′″ transferred bythe picking means 150 from the storage means to the delivery containerDT.

It will be appreciated that the multiple inventory items 28 need not befor the same customer order and as the items 28 can be picked frommultiple bins, they can be deposited in multiple delivery containers DT.

This may be particularly useful if inventory items 28′, 28″ and 28′″ arelocated closely together in the storage system.

FIG. 11 a shows a further aspect of the invention. As can be seen inFIG. 11 a , the storage system or a part thereof comprises roboticpicking means 350 located at one edge of the system. The robotic pickingmeans 350 is movably mounted on track means 360. The picking means 350may be moved along the track under the control of a central utility. Therobotic device 350 may be powered directly from a suitable fixed powersupply.

Advantageously in this aspect of the invention, the robotic pickingmeans 350 need not be battery powered and may be more substantial thanthe picking means 150 contained in the cavity of a robotic pickingdevice. It will be appreciated that the robotic picking means 350 may befixedly mounted to suitable mounting means. The mounting means mayinclude be not be limited to structural members of the building orinstallation containing the storage system or purpose built mountingmeans such as cross beams or RSJs.

In use, robotic load handling devices 30 position bins 10, containinginventory items 28 to be picked, and delivery containers DT, requiringthe inventory items 28 in the bins 10 positioned by the robotic loadhandling devices 30, adjacent the robotic picking device. Under thecontrol of the centralised control utility, the picking means 350 picksan inventory item from a bin 10 and places it in a target deliverycontainer DT. The picking process continues in this manner until all thedelivery containers requiring said inventory items 28 have beenserviced. At this point, load handling devices 30 may remove thedelivery containers DT that do not require further inventory items andmove to dispatch or in to a storage part of the main grid.

It will be appreciated that this method of on grid picking requiressubstantially less movement of robotic devices around the grid to pickinventory items.

FIGS. 12 a-12 b shows an alternative arrangement of the robotic pickingmeans 350 described above with reference to FIGS. 11 a and 11 b . InFIGS. 12 a-12 b the robotic picking means 450 is suspended from a gantrycrane 480. The robotic picking means 450 is suspended from suitablebeams located around the periphery of the grid 22. As shown in FIG. 12 a, the robotic picking means 450 can pick from any of the bins 10 ordelivery containers located on the top of the stacks 12 beneath thegrid.

The picking means 450 operates in a similar fashion to that describedwith reference to FIG. 11 b with the advantage that the whole grid 22can be accessed.

Should the removal of an inventory item 28 from a delivery container 10result in the delivery container DT being empty, it may become adelivery container DT for a different customer order or be returned tostorage or to goods inbound to have further inventory items 28 locatedtherein.

In this way, congestion at a manual pick station is avoided. Inaddition, a pick station, whether for manual or robotic picking,represents a significant investment. For items which can effectively bepicked using the present invention, the overall investment for a givenpicking capacity can be significantly reduced. It will be appreciatedthat certain orders may be completely pickable without accessing thenormal pick stations.

It will further be appreciated that using a robotic picking-area that isonly, for example, one bin 10 deep as shown in FIG. 5 , may allow theoverall capacity of a given warehouse to be increased, since otherwiseunused space may become productive.

Moreover, the robotic picking portion 100 of the storage and pickingsystem may comprise chilled or ambient sections to enable picked ordersto be retained for a period of time before being loaded to deliveryvehicles and dispatched. It will be appreciated that grid size andaverage stay time in the DT dispatch area is driven by the density ofthe robotic load handling devices 30, 130 on the grid so shorter leadtimes could be accommodated, especially if low frequency items couldalso be picked manually at the pick stations.

Furthermore, the above mentioned aspect of the invention may be combinedwith high speed stationary robotic load handling devices for certaininventory items 28 that are considered to be fast moving, as previouslydisclosed in UK Patent Application No. GB1502123.1— Ocado InnovationLimited.

Furthermore, it will be appreciated that the picker devices 30, 130,230, 330 and 430 may further comprise sensor means to ensure the pickedinventory item 28 is delivered to the correct delivery container DTand/or the correct part of the delivery container DT. Deliverycontainers DT may comprise a number of bags and said sensor means may beused to ensure correct positioning of inventory items 28 within bags inthe delivery containers DT.

It will be appreciated that whilst the above embodiments are describedwith reference to the bins 10 being of substantially the same shape andconfiguration, the system may be adapted to utilise bins and deliverycontainers of alternative shapes, sizes and configurations. In thissituation, robotic load handling devices and robotic picking deviceswould need to be provided within the system capable of handlingdifferently shaped and sized bins and containers. Furthermore, certainareas of the storage system may be adapted to handle alternative sizesof containers and bins.

It will further be appreciated that the picking means disposed above thegrid 22 need not be a robotic device 30 but may comprise an operatorhaving access to the grid 22 to pick inventory items 28 directly frombins 10 to transfer them to delivery containers DT. The operator maytravel on a robotic service device.

In a further aspect of the invention, the robotic picking and storagesystem described above with reference to FIGS. 1 to 4 comprises bins 10performing different functions. It will be appreciated that the bins 10described below may be used in association with any of the robotic loadhandling devices 30 described above.

In the further embodiment of the invention, derivatives 410 of the bins10 comprise a mechanism for dispensing one or more of a plurality ofinventory items 28 from the base of the bin 410. As shown in FIGS. 13a-13 d through to 18 b a bin 410 may comprise numerous mechanisms forachieving this. Each mechanism is described in detail below. However, itwill be appreciated that the object to be achieved in all cases issubstantially the same—the ability to deposit an inventory item 28, orsimilar in to a delivery container DT located beneath a bin 410, therebyavoiding the need to transport bins 10 containing inventory items 28 topick stations beneath the framework 14 of the storage system.

With reference to FIGS. 13 a-13 d , a bin 410 is shown having 8dispensing devices 56 disposed within a single bin 410. It will beappreciated that the number of dispensing devices may be variedaccording to the size and shape of the inventory items 28 to be storedin the bins 410.

The dispensing devices 56 disposed within the bin 410 of FIGS. 13 a, 13b and 13 c comprises a conventional vending machine mechanism whereby asingle inventory item 28 may be dispensed from a given dispensing device56. It will be appreciated that the inventory items 28 stored maycomprise a number of different items of a number of different categoriesin each bin 410. Alternatively every dispensing device within a singlebin 410 may comprise the same inventory item 28.

In use, in response to an electrical, mechanical or electromechanicalinput to the dispensing means, a single or several inventory items 28may be dispensed from the base of the dispensing means via an opening inthe base of the bin 410. The base of the dispensing means must cooperatewith the base of the bin 410 to ensure the inventory item to bedispensed is ejected from the base of the bin 410. It will beappreciated that the number of dispensing means disposed within each bindepends on the size of the inventory items 28 to be dispensed.Furthermore, it will be appreciated that any given customer order mayrequire a plurality of the same inventory items 28 therefore thedispensing device must be able to dispense single or multiple inventoryitems 28 of a given variety.

The opening in the base of the bin 410 may be a flap, two co-operatingflaps, a rolling shutter or any other suitable opening or closing meanscapable of remote or autonomous. It will be appreciated that the loadhandling device 30 carrying such a dispensing bin 410 may receive acommand from the central utility to transport the dispenser-type bin toa given position above a delivery container DT in a robotic pickingarea. The robotic load handling device 30 may then be provided withmeans for activating the dispensing device in the bin 410 in order forthe inventory items 28 to be deposited in delivery containers DTdeposited below the dispenser bin 410. The command received andtransmitted via the robotic load handling device may be controlled viamechanical, electrical, electromechanical or wireless means with theappropriate sensors being disposed in the bins 410 or the robotic loadhandling devices 30 described above. The sensors may be located in thebin gripper assembly 39 described above, however other suitable meansmay be used.

It will further be appreciated that the command may be given in numerousways. For example, the command may be “Go to position x there anddispense on arrival”, or the command may be issued in two sections,rather first “go to position x” and then “dispense”.

Furthermore, as shown in FIGS. 13 a, 13 b and 13 c the bin 410 maycomprise a permanent opening 58 in the base 58, the dispensing means 56acting so as to move and eject the target inventory item 28 out of thepermanent opening 58.

It will be appreciated that the inventory items 28 packed in tocassettes in the dispenser bin 410 may be the same or may be different.Furthermore, it will be appreciated that the any of the robotic pickingdevices described above may pick cassettes 56 from a bin 10 and compilethem in to a single bin thereby creating a customised bin 10 that maythen be transported by a suitable picking device to multiple deliverycontainers DT and the required number of items 28 be dispensed. In thisway the robotic picking device makes a customised bin 10 such that thebin may be transported around the system in the manner described aboveto deposit inventory items 28 in delivery containers.

In use, in the storage, picking and dispatch system described above,such a dispensing bin 410 may be used in several circumstances. Firstly,inbound inventory items 28 may be unpacked and loaded in to dispensingbins 410. Once loaded with required inventory items 28, a robotic loadhandling device of any of the types described above may be used totransport the dispensing bin to the robotic picking portion of thestorage system. However, it will be appreciated that the load handlingdevice 30 will require means for activating the dispensing means 56 todeposit the or each inventory item through the opening 58 in the base ofthe bin 410.

As shown in FIGS. 14 a-14 e , once in position above a deliverycontainer DT requiring an inventory item from said dispensing bin 410,the dispensing mechanism is activated by appropriate communication meansbetween the robotic load handling device 30 and the dispensing bin, anda required inventory item 28 is deposited in to the delivery containerDT located beneath the grid in the robotic picking portion of thestorage system.

Once the inventory items 28 have been deposited in the required deliverycontainers DT the dispensing bin 410 may be returned by the robotic loadhandling device 30 to the goods inbound portion of the system to berefilled or it may be returned to the main storage system for storage ina stack 12 until the inventory items 28 are required again.

In this situation, the order in the delivery container DT may becomplete in which case the container DT may be transported by roboticload handling devices 30 to a van or a dispatch station for onwarddelivery. However, if the order has not been fulfilled the deliverycontainer DT may be kept in the robotic picking portion of the storagesystem awaiting further inventory items 28 to be deposited therein.Moreover, the delivery container DT may require transport to aconventional pick station to have further inventory items 28 addedthereto in a manual or robotic manner. Furthermore, if the order iscompleted but there is a delay before dispatch can occur, the deliverycontainer DT may be transported to the main storage system and storedtherein until a delivery time is known.

In a further embodiment of the third aspect of the invention, as shownin FIG. 14 a bin 510 has one or more opening or hatch 60 in its base toallow items contained in the bin 510 to fall from the bin 510 to adelivery container DT located below in the bin 510. In this manner thebin 510 may be considered a dispenser bin 510 as described above.However, in this form of bin 10, the entire contents of the bin 510 isdeposited in the delivery container DT when the bin 510 is in situ overthe required delivery container DT

Referring to FIGS. 14 a and 14 b preferably the whole of the base 75 iscomprised of one or more moveable panel 65. When the one or moremoveable panel or panels is in its fully open second position shown inFIGS. 14 a, 14 b and 14 c the hatch 60 extends across the whole of thebase 75 of the bin 10. As the hatch is the same size as the base of thebin 510 even very large items can be reliably dispensed to the deliverycontainer DT underneath the bin 510.

As shown in FIGS. 14 a, 14 b and 14 c one or more slideable panel movesfrom a first closed position shown in FIG. 14 a to a second openposition shown in FIG. 14 b . In the first position the panels 65 abutthe sides of the bin 10 as shown in FIG. 14 a to form a continuous base.

This embodiment has the advantage that there is little risk of itemsbecoming stuck between the panel and the side 70 of bin 510. It has thefurther advantage that there is little or no risk of the slideablepanels being impeded by the contents of bin 510 or the contents of thedelivery container DT underneath bin 510.

One form of mechanism for moving the panel 65 from a closed to an openposition is shown in FIG. 14 d . The mechanism comprises a roller typemechanism for rolling the panel 65 from an open position to a closedposition as shown in FIG. 14 c.

As shown in FIG. 14 e , in use a robotic load handling device 30 carriesa dispenser bin 510 in accordance with one form of the invention and ismoved in to position above a target delivery container DT. The dispenserbin 510 is activated via the central control utility and/or via therobotic load handling device and the item stored in the bin 510 dropsthrough the opening in the base of the bin 510 in to the deliverycontainer located below.

In another preferred embodiment as shown in FIGS. 15 a and 15 b , shownone or more slideable panels is provided. In the first position thepanels abut or overlap against one another or the side 70 of the bin 510as shown in FIGS. 15 a to 15 b to form a continuous base and close thehatch 60. In the second position the slideable panel or panels may beindependently opened thereby allowing the content of the bin 510immediately above the panel activated to be deposited in the deliverycontainer DT beneath the robotic load handling device 30 carrying thebin 510.

The bin 410 of FIGS. 16 a-16 b may comprise an inventory item 28 permovable panel as shown. Alternatively there may be a plurality of itemsper panel, the panel only being opened enough to allow a single item tobe dispensed

In a further embodiment of dispenser bin 510, for example, as shown inFIGS. 16 a-16 b and 17, the bin 510 comprises a hatch 60 which isreleasably opened and closed by one or more moveable panels or flaps 65.The panels may be flexible, elastic, deformable, continuous ordiscontinuous or of any suitable form for moving from an open to aclosed position.

The panels can be moved between a first or closed position shown insecond or open position where the hatch 60 is fully or partially openunder the control of the controller utility or the load handling device30.

In a preferred embodiment shown in FIG. 16 a-16 b the bin 510 has sides70 a, and 70 b and a base 75 formed by a pair of pivotable panels orflaps 65 a and 65 b.

In the first closed position the flaps abut or overlap one another toform a continuous base 65 which retains the contents of bin 510 as shownin FIG. 17 .

In the second open position the flaps 65 a and 65 b pivot and openoutwards towards the delivery container DT beneath the bin 510 to allowthe contents of the bin 510 to fall into the delivery container DTunderneath bin 510.

The two or more pivotable panels 65 a and 65 b can be moved together orindependently by the controller utility in direct communication with thebin 510 or via a communication with the robotic load handling device 30carrying the bin 510, from the first position to the second openposition to dispense the contents of the bin 510 into the deliverycontainer DT underneath bin 510. The panels 65 a and 65 b can then bereturned to the first closed position to ready the bin 510 to receiveother inventory items 28.

It will be appreciated that pivotable panels 65 a and 65 b may beprovided which open inwardly.

It will further be appreciated that pivotable panels 65 a and 65 b maybe provided which can open inwardly and outwardly.

In an alternative embodiment, the bin 510 may be divided into two ormore compartments A and B each of which is provided with one or morepivotable panels 65 which can be independently moved from a first closedposition to a second open position to dispense the contents of one ofthe compartments to the bin underneath bin 510A.

In an alternative embodiment, several abutting or overlapping panelsform the base of the bin 510 in the first closed position. The panelscan be rotated by the controller to a second position so that theyoverlap in the case of the abutting panels or overlap more in the caseof the overlapping panels to provide a hatch 60 through which items canbe dispensed from bin 510 to the delivery container DT underneath thebin 510. The size of the hatch can be varied by varying the amount ofoverlap of the panels in the second open position.

In an alternative embodiment the hatch 60 only extends across a part ofthe base 75. One or more moveable panels 65 are provided which in afirst or closed position cover the hatch 60 and retain the contents ofbin 510. The one or more panels 65 can be independently moved away fromthe hatch to a second position where the hatch is partially or fullyopened so that items in bin 510A fall through the hatch to the binunderneath bin 510A.

In further embodiments the one or more panels 60 move laterally from thefirst to the second position. It will be appreciated that alternativelya single panel 60 may be provided which moves bilaterally.

It will be appreciated that when two or more panels 60 are provided theycan abut or overlap one another in the first position to close thehatch.

It will be appreciated that when two or more panels 65 are provided eachpanel can be moved independently of the others.

It will be appreciated that several hatches may be provided in the baseeach closed by one or more moveable panel.

It will be appreciated that by varying the second position of the one ormore panels the hatch can be partially or fully opened to dispense someor all of the contents of bin 510 into the delivery container DTunderneath. This may be especially preferred when there is a need todispense small items and retain larger items. Alternatively this may beespecially preferred when dispensing fluids or free flowing items suchas by way of example only grain, detergent, sugar, or like powders,packaging materials or beads, novelty items such as sweets, glitter orsmall toys, or liquids.

It will be appreciated that a flexible, or elastic layer may extend fromthe hatch to act as a funnel or channel to direct items towards thehatch.

It will be appreciated that in an alternative embodiment the base of thebin comprises an elastic layer having openings or valves through whichheavier items can be dispensed. The opening or openings may be sizedsuch that the weight of the item to be dispensed is sufficient to conveythe item through the opening 60. Alternatively the opening or openingsmay be sized and shaped to only dispense items from bin 510 to thedelivery container DT under bin 510 when other items in the bin 510press on the item or items to be dispensed.

It will be appreciated that in an alternative embodiment the base of thebin comprises a net so that small items fall through the bin 510 to thedelivery container underneath the bin 510.

It will be appreciated that dispenser bins described in this embodimentmay only carry a single item. However, the dispenser bin 510 may carry anumber of items each located on a separately openable and closeableportion of the base of the bin, as shown in FIG. 14 a.

In use, a robotic load handling or picking device 30 as described in anyof the embodiments above transports the dispensing bin 510 to a gridposition on the robotic picking grid above a delivery containerrequiring the inventory item 28 in the dispenser bin. A signal isapplied to a releasable opening mechanism in the dispensing bin 510 orto the robotic load handling device carrying the bin 510, the signalacting so as to release the opening mechanism in the dispensing bin, theinventory item 28 being deposited in the delivery container DT.

The dispenser bin 510 may be provided with verification means to verifythat the item or items dispensed are deposited in the correct deliverycontainer DT or in the correct portion of the correct delivery containerDT.

In a further aspect of the invention as shown in FIGS. 18 a and 18 b ,the bin 10 comprises a form of hopper for containing ‘free flowing’inventory items such as sweets, liquids, flour, nuts and bolts or othersuch inventory items 28. The bin 810 may comprise separate hopper-typesections containing different categories of inventory item 28 or maycomprise a bin 910 having a single hopper type unit containing a singlecategory of inventory item 28.

In use, the bin 10 comprising said hopper-type dispenser bin istransported by a robotic load handling or picking device 30 as describedin any of the embodiments above. The device transports the dispensingbin 810, 910 to a grid position on the robotic picking grid above adelivery container DT requiring the inventory item 28 in the dispenserbin 810, 910. A signal is applied to a releasable opening mechanism 61in the dispensing bin 810, 910 or to the robotic load handling devicecarrying the bin 810, 910, the signal acting so as to release the oreach opening mechanism 61 in the dispensing bin, the inventory item 28being deposited in the delivery container DT.

It will be appreciated in the case of the dispenser bin 810 that eachsection requires a releasable opening mechanism 61 such that inventoryitems 28 may be dispensed, using sensor and camera means as appropriate,in to the correct section of the delivery container DT.

It should be noted that the delivery container DT may be an actualdelivery container for onward transmission to the customer or be a bin10 with “post pick” items destined for delivery to somewhere else, forinstance to an alternative fulfilment centre. The term deliverycontainer DT is used to distinguish bins 10 from delivery containers DT.However, it will be appreciated that bins and DTs may be of a similar orsubstantially the same shape and configuration, the function of the bindefining the definition rather than any change in the actual shape orsize of the bin.

It will also be appreciated that the delivery container DT may becontained within a bin 10 to ensure that the robotic load handlingdevices can handle the movement of all bins whether in the stacks 12 ofthe main storage system or in a nominal robotic picking area.

It will further be appreciated that whilst many of the above embodimentsare described with reference to a remote or separate robotic pickingarea, it is possible that the main storage system be used as a roboticpicking area at the same time as functioning as a conventional pickingand storage system.

1. A combination of a picking system within a storage system, thecombination comprising: a first set of parallel rails or tracks and asecond set of parallel rails or tracks extending substantiallyperpendicularly to the first set in a substantially horizontal plane toform a grid pattern with a plurality of grid spaces; a set of uprights,the uprights supporting the first and second sets of rails or tracks,the uprights and rails or tracks together defining a framework; aplurality of storage containers located beneath the first and secondsets of rails or tracks and within the framework, a portion of thestorage containers occupying a space below a grid space; and a pluralityof robotic devices including an opening in a top surface of each roboticdevice, thereby extending a cavity through the robotic device enablingaccess to contents of a storage container or first delivery container DTwithin the cavity of the robotic device, wherein the robotic device islocated on the grid of the storage system; and a robotic picker adaptedto access the content of the storage container or first deliverycontainer DT located within the cavity of one of the plurality ofrobotic devices located on the grid of the storage system wherein therobotic picker is adapted to pick an inventory item from the one of theplurality of robotic devices and to place the inventory item in a secondrobotic device including a second delivery container DT.
 2. Thecombination according to claim 1, wherein the storage container or thefirst delivery container DT is configured to be lifted from the storagesystem in to the extended cavity of the robotic device.
 3. Thecombination according to claim 2, wherein when the storage container orthe first delivery container DT is in situ in the robotic device, thestorage container or the first delivery container DT is exposed at thetop surface of the robotic device, enabling inventory items to be pickeddirectly in to the second delivery container DT.
 4. The combinationaccording to claim 2, wherein lifting means, and container grippingmechanism are located to the sides of each of the plurality of roboticdevices.
 5. The combination according to claim 1, wherein the pluralityof robotic devices each have one or more overhanging sections.
 6. Thecombination according to claim 5, wherein the plurality of roboticdevices each have an overhanging section on only one side of the roboticdevice.
 7. The combination according to claim 1, wherein the pluralityof robotic devices are each arranged to occupy only a single space ofthe grid.
 8. The combination according to claim 1, wherein the roboticpicking area of the storage system is only one container deep.
 9. Thecombination according to claim 1, wherein the plurality of roboticdevices further comprise sensors configured to ensure that inventoryitems are delivered to the correct second delivery container DT and/orthe correct part of the second delivery container DT.
 10. Thecombination according to claim 1, wherein the robotic picker is movablymounted on an edge of the storage system, the robotic picker configuredto pick an inventory item from within a portion of the storage systemand deposit the inventory item within a third delivery container DTlocated in the storage system.
 11. The combination according to claim 1,wherein the robotic picker is suspended above the storage system. 12.The combination according to claim 11, wherein a plurality of roboticpickers are suspended from the ceiling above the storage system.
 13. Thecombination according to claim 11, wherein the robotic picker issuspended at a fixed point from the ceiling above the storage system.14. The combination according to claim 11, wherein the robotic picker ismovably mounted above the storage system, the robotic picker beingmovable to positions above any storage container or delivery containerwithin the storage system, the robotic picker being adapted so as topick inventory items directly from at least one storage container anddeposit the or each item in at least one third delivery container DT.15. The combination according to claim 11, wherein the robotic picker islocated on a beam, moveable in the x-y direction above the storagesystem to locate the robotic picker at required points above the storagesystem.
 16. The combination according to claim 11, wherein the roboticpicker is movable under the control of a centralized control utility.17. The combination according to claim 1, wherein a number of roboticdevices of the plurality of robotic devices containing the storagecontainers or the first delivery containers DT including inventory itemsrequired to fulfill customer orders are positioned within reach of therobotic picker.
 18. The combination according to claim 1, wherein therobotic picker picks from a number of storage containers of theplurality of storage containers located within reach, to the firstdelivery container DT located in a robotic device.
 19. The combinationaccording to claim 1, wherein a robotic device of the plurality ofrobotic devices having the first delivery container DT in situ, ispositioned centrally surrounded by robotic devices of the plurality ofrobotic devices each having a storage container in situ.
 20. Thecombination according to claim 1, wherein the robotic picker is arrangedto have sufficient reach to pick from the storage containers located insitu of the plurality of robotic devices or from storage containers ofthe plurality of storage containers located in the storage systembeneath the grid.